T I T L E :

ANALYSIS ON MALAYSIAN SHIPYARD LAYOUT AND ITS EFFECTIVENESS TOWARDS

IMPROVING THE PRODUCTIVITY

BY:MOHD ZULHILMI BIN ZALIZAN

56267109180BET NAVAL ARCHITECTURE & SHIPBUILDING

SUPERVISOR:

CEngr. AHMAD AZMEER BIN ROSLEE

Introduction Literature Review Research Methodology Data Analysis Proposed Layout & Efficiency Analysis Discussion Recommendation & Conclusion

RESEARCH OUTLINE

INTRODUCTION

INTRODUCTION

Shipyard layout is one of the important elements that determine the productivity of the shipyard.

However, direct relationship between shipyard layout and its productivity is still in grey area due to the fact :

Productivity is a measure of efficiency of production.

Productivity is normally not considered during layout design.

RESEARCH BACKGROUND

What this topic all about?

Analyze how much the layout of a shipyard contribute to its productivity

Main concern : i. Existing Layoutii. Timeiii. Distanceiv. Facilities and Workers

Study its benefits to the whole shipyard process

RESEARCH BACKGROUND

Importance of this studies

Currently, there is not enough information about Malaysian shipyard layout.

Ideal layout for a modern shipyard is based on production flow basis

The study will cover the layout effectiveness in term of its productivity.

RESEARCH BACKGROUND

How to complete the task and achieve accurate result throughout all process during research?

Divided into three parts :i. Visit and Surveyii. Data Collection and Analysisiii. Design Phase

How to calculate productivity :i. By measure on the distanceii. By measure on the time taken

PROBLEM STATEMENT

What is the time consumed for shipbuilding activities based on the current shipyard layout?

How can the productivity increased by changing the layout?

OBJECTIVES OF THE RESEARCH

To identify selected shipbuilding process work flow, distance of movement of workers or products and the time taken for each activity of it.

To study current selected shipbuilding layout effect on the productivity of the shipbuilding.

To do evaluation of productivity for the current shipbuilding layout.

To propose the suitable shipbuilding layout.

SCOPE OF RESEARCH

Selected Shipyard NGV Tech. Sdn. Bhd., Teluk Panglima Garang, Selangor

Nature of Business Aluminium & Steel Vessel Shipbuilding

Productivity will be based on the distance and time measured on the selected shipyard

Project Basis – Steel Tugboats, Workboats, & Supply Boats

LITERATURE REVIEW

“The past two or three decades have seen the emergence of a substantial number of new shipyards, primarily in Asia and Eastern Europe, that have been specifically planned to construct the larger ships being ordered today, using contemporary shipbuilding practices and production methods.”

Ship Construction 6th Edition, DJ Eyres2006, Publisher by Elsevier Ltd.

LITERATURE REVIEW

LITERATURE REVIEW

“ Malaysia’s shipyard productivity data is nowhere to be seen. It is very hard to use this data and if it is there, it is not presentable. Malaysian Industrial Development Authority (MIDA), a government arm to promote local industries does not have any data on shipbuilding industry ”

Malaysian Industrial Development Authority www.mida.gov.my

LITERATURE REVIEW

“Productivity can be termed as an index that measures output (goods or services) relative to the input (labor, materials, energy and other resources) used to produce them.”

William J. StevensonProductions/Operation Management, Sixth Edition,

Irwin/McGraw Hill, US, 1999

LITERATURE REVIEW

“Despite the importance of Productivity Measurement in representing company’s competitiveness, its implementation in Malaysia’s shipyard has not widely known and properly documented.”

Case Study 1Ahmad Azmeer Bin Roslee

Universiti Teknologi MalaysiaMaster in Marine Technology

LITERATURE REVIEW

“Ship production involved many stages of fabrication processes, it is expected that dimension variances could occurred and if it is not managed properly it will cause related problems which will lead to rework and delay.”

Case Study 2Ronny Andalas

Universiti Teknologi MalaysiaMaster in Marine Technology

LITERATURE REVIEW

“Shipyard layout management may justly must be termed as an art when one consider the varying degrees of success attained by one men in the different position and having the same tools with which to work”

Case Study 3Lim Cheng Min

Massachusetts Institute of TechnologyMaster of Science in Naval Construction and Engineering

RESEARCH METHODOLOGY

Title Proposal

Thesis Objective

Research Methodology

Survey Form

Decide Shipyard for Survey

Produced Proposed Layout

Final Report

Literature Review

Task Planning

Result

Accept?

Data Analysis

Survey/Data collected

Shipyard Visit

YES?

NO?

FLOW CHART

Phase 1JULY 2011 – JAN 2012

Phase 2JAN 2012 – MAY 2012

Data Collected

Enough

Data Tabulated

Data Analysis

YES?

NO?

Start

Result

Finish

FLOW CHART (SURVEY)

OPERATION PROCEDURE

Select shipyard and pilot test to develop productivity measurement form.

OPERATION PROCEDURE

Obtain the existing layout.

Record all findings using productivity measurement form. Measure and collect data based on :

i. Distanceii. Time Taken

OPERATION PROCEDURE

• Productivity Measurement Form

OPERATION PROCEDURE

Do an analysis.

Suggest new layout with new improvement :i. Less distanceii. Less time taken

Analysis Work Flow

PROJECT ACTIVITIES (FYP1)

Projection Aug 2011 – Dec 2011

PROJECT ACTIVITIES (FYP2)

Projection Jan 2012 – May 2012

DATA ANALYSIS

CONCENTRATED AREA

CONCENTRATED AREA

Back

CONCENTRATED AREA

Location Description3 Jetty

8 Slipway 1

11 Hangar 3

12 Hangar 4

13 Hangar 5

14 Store 1 (Tools & Equipments)

15 Store 2 (Paintings)

17 Store CO2 (Materials)

21 Workshop 1

25 Client & Contractor Office

27 NGV Main Office

28 Surau

29 Canteen

Area decided based on project consideration (steel-construction)

Currently is the busiest part of shipyard Current activities : 2 x 52m Multipurpose Utility Vessel

: 3 x 30m Offshore Mooring Tug Upcoming : 2 x 52m Multipurpose Utility Vessel

: 2 x Navy Vessel

Area targeted consumed more time based on distance travelled.

CONCENTRATED AREA

PROJECT DESCRIPTION

PROJECT DESCRIPTION

Data taken from observation on movements of workers

Some movements were basically based on rules and regulation of shipyard.

eg. every workers must punched card at main office before and after going to have their rest period (lunch time)

Start-stop point of time calculated from exit-to-entrance of each location

DATA COLLECTION

There are 23 from-to section recorded.

Categorized as Section A-Weg. Section A is movement from Location 27 to Location 25

Section B is movement from Location 27 to Location 21

There are 5 types of movement Walk Motorcycle Car / Van Lorry Forklift

There have been some different paths recorded for walking movements

DATA COLLECTION

FREQUENCY

SectionNo. of Data Collected

A 16B 13C 22D 32E 12F 28G 25H 42I 48J 0K 47L 48M 40N 15O 43P 41Q 6R 40S 49T 41U 37V 43W 24

A B C D E F G H I J K L M N O P Q R S T U V W0

10

20

30

40

50

60

No. of Data Collected

No. of Data Collected

Sequence : S, I, L, K, O, V, H, P, T, M, R, U, D, F, G, W, C, A, N, B, E, Q, J

Time average is calculated based on total time consumed in each section and divided by their frequency

TIME AVERAGE

Back

Time Average (seconds)Section Location covered Distance (m) Walk Motorcycle Car / Van Lorry Forklift

A 27 to 25 33 27.79 9.69 B 27 to 21 39 26.63 10.61 C 27 to 15 72 56.17 15.79 D 27 to 14 114 95.21 29.16 61.37 E 29 to 14 24 36.35 F 29 to 27 102 90.12 29.76 53.60 G 14 to 11 walk:177, others:240 218.27 68.44 127.92 156.66 H 14 to 8 walk:216, others:254.1 330.41 60.75 143.00 157.49 202.26I 14 to 12 366.3 416.20 87.69 198.34 247.53 250.70J 14 to 13 389.4 K 14 to 21 92.4 102.85 25.74 53.42 59.34 57.48L 14 to 17 234.3 215.85 87.69 123.00 140.38 119.24M 14 to 3 534.6 130.39 279.46 323.21 345.60N 17 to 11 72.6 18.91 43.32 45.41 121.57O 17 to 8 49.5 65.02 16.09 31.41 33.60 119.85P 17 to 12 112.2 143.41 28.37 59.95 82.27 138.57Q 17 to 13 138.7 105.25 166.25R 17 to 3 273.9 247.83 89.68 140.58 165.53 248.40S 12 to 3 walk:138.6, others:178.2 130.73 28.95 70.94 71.87 173.83T 8 to 3 walk:150, others:240.9 177.04 52.42 103.68 91.77 223.80U 11 to 3 walk:207.6, others:297 246.79 74.18 131.68 140.87 275.61V 21 to 3 396.0 112.43 141.59 195.42 395.59W 27 to 3 346.5 145.38 167.15

DATA ANALYSIS (STRING DIAGRAM)

From string diagram, we can study on : Repetitive Safety Requirement Cross Traffic

PROPOSED LAYOUT&

EFFICIENCY ANALYSIS

Factors concerned : Distance – affecting times per distance travelled Process Flow Safety Factor (Safe & Mandatory Zone) Transportation Access Backtracking (Actual Layout vs. Proposed Layout) Geographic Requirement (riverside for launching)

PROPOSED LAYOUT

PROPOSED LAYOUT

Back

1 2 3 4 5 = (3 - 4)Section Location covered Distance (m) Distancenew(m) Distance Reduced (m)

A 27 to 25 33.0 32.8 0.2B 27 to 21 39.0 94.5 -55.5C 27 to 15 72.0 126.3 -54.3D 27 to 14 114.0 185.0 -71.0E 29 to 14 24.0 151.5 -127.5F 29 to 27 102.0 36.6 65.4

Gwalk 14 to 11 177.0 55.5 121.5Gothers 240.0 55.5 184.5Hwalk 14 to 8 216.0 41.8 174.2

Hothers 254.1 41.8 212.3I 14 to 12 366.3 83.8 282.5J 14 to 13 389.4 98.9 290.5K 14 to 21 92.4 67.3 25.1L 14 to 17 234.3 37.0 197.3M 14 to 3 534.6 239.6 295.0N 17 to 11 72.6 81.7 -9.1O 17 to 8 49.5 57.1 -7.6P 17 to 12 112.2 61.5 50.7Q 17 to 13 138.7 69.4 69.3R 17 to 3 273.9 207.9 66.0

Swalk 12 to 3 138.6 134.5 4.1Sothers 178.2 175.9 2.3Twalk 8 to 3 150.0 150.0 0.0

Tothers 240.9 218.3 22.6Uwalk 11 to 3 207.6 207.6 0.0

Uothers 297.0 265.4 31.6V 21 to 3 396.0 304.4 91.6W 27 to 3 346.5 422.8 -76.3

Total Total5489.80 3704.40

DISTANCE REDUCED

Total Distance Reduced :5489.8m – 3704.4m= 1785.4m @ 32.5%

EFFICIENCY ANALYSIS

Analysis Table for Walk1 2 3 4 = (3 ÷ 2) 5 6 = (4 X 5)

Section Distance (m) Timeaverage (s) Time per Meter (s/m) Distancenew(m) Timenew (s)A 33.0 27.79 0.84 32.8 27.62B 39.0 26.63 0.68 94.5 64.53C 72.0 56.17 0.78 126.3 98.52D 114.0 95.21 0.84 185.0 154.51E 24.0 36.35 1.51 151.5 229.46F 102.0 90.12 0.88 36.6 32.34G 177.0 218.27 1.23 55.5 68.44H 216.0 330.41 1.53 41.8 63.94I 366.3 416.20 1.14 83.8 95.21J 389.4 98.9 K 92.4 102.85 1.11 67.3 74.91L 234.3 215.85 0.92 37.0 34.09M 534.6 239.6 N 72.6 81.7 O 49.5 65.02 1.31 57.1 75.00P 112.2 143.41 1.28 61.5 78.61Q 138.7 69.4 R 273.9 247.83 0.90 207.9 188.11S 138.6 130.73 0.94 134.5 126.86T 150.0 177.04 1.18 150.0 177.04U 207.6 246.79 1.19 207.6 246.79V 396.0 304.4 W 346.5 422.8

Total Total2626.66 1835.98

Time Average Table

Full Analysis

EFFICIENCY ANALYSIS

Table of Efficiency Analysis

Types of Movement (Total Timeavg - Total Timenew) / Total Timeavg Efficiency Increased (%)

Walk 0.301 30.1

Motorcycle 0.298 29.8

Car / Van 0.368 36.8

Lorry 0.468 46.8

Forklift 0.347 34.7

Types of Movement Efficiencydefault (%) Efficiencynew (%)

Walk 100 130.1

Motorcycle 100 129.8

Car / Van 100 136.8

Lorry 100 146.8

Forklift 100 134.7

EFFICIENCY ANALYSIS

WalkMotorcycle

Car / VanLorry

Forklift

0

20

40

60

80

100

120

140

160

Efficiencydefault (%)

Efficiencynew (%)

Efficiencydefault (%)Efficiencynew (%)

DISCUSSION

Besides manipulating distance to reduce the time, this will eventually contribute to cost effectiveness

eg. less fuel consumed in transportation movement

Some facilities cannot be changed due to restriction based on several factors

Increase “quality” man-hour with the same labor cost

More systematic flow of operation

Proper safety control and management

Less time, higher productivity, more profits

DISCUSSION

RECOMMENDATION&

CONCLUSION

Proper syllabus for studies on shipyard productivity.

Commence current studies to higher degree and relate to the OECD.

Perpetual cooperation between universities and shipyards towards improving the shipbuilding productivity in Malaysia.

Additional supports by universities in terms of

cash, access to information, accommodation, etc

RECOMMENDATION

CONCLUSION

The result from this studies can be a turning point on improving the selected shipyard productivity.

Distance and Time are 2 factors that play an important roles in determining the efficiency of a shipyard layout thus improving the productivity and occasionally increase the profits

The result will also help the shipyard owner to overcome several problems by reducing the time and distance taken.

THANK YOU

Q & A SESSION